Methodology for Cutting Tool Selection System Based on STEP NC. Part 1: Development of Tool Management System According to ISO13399 Standard

Hanae ZARKTIet.al. Int. Journal of Engineering Research and Application www.ijera.com ISSN: 2248-9622, Vol. 7, Issue 9, (Part -7) September 2017, pp.46-52

RESEARCH ARTICLE OPEN ACCESS

Methodology for Cutting tool selection system based on STEP_NC. Part 1: Development of tool Management system according to ISO13399 standard

Hanae ZARKTI*, Abdelilah EL MESBAHI*, Ahmed RECHIA* *(Research team in Engineering, Innovation and Management of Industrial Systems, Department of mechanics, Abdelmalek Essaadi University, Faculty of sciences and technics, Tangier, Morocco. Corresponding Author: Hanae ZARKTI

ABSTRACT Computer aided process planning (CAPP) systems are considered as an important interface between computer aided design and computer aided manufacturing systems. One of the main objectives of CAPP systems is to assign adequate tools to manufacture the part. In fact, selecting the best tool is a critical activity and depends on numerous factors related essentially to the part and tool characteristics, machining conditions, etc. This paper describes a methodology for cutting tool selection based on STEP_NC and using tool definition according to ISO 13399 standard. The main focus was on milling process. A study of influencing parameters was conducted and some concluding remarks were made. The paper emphasizes the importance of the definition of cutting tools according to STEP-NC and ISO13399 standards in data tool exchange and proposes an automated optimized methodology for cutting tool selection. In this paper, a database was developed to ensure management of cutting tool using MySQL SERVER. Data tool were extracted from Sandvik Corormant ISO 13399 product library, by development of a new software using object oriented approach. Keywords: Cutting tool selection, STEP_NC, ISO13399,Object oriented programming, database.

I. INTRODUCTION Mookhrejee and Bhattacharyya [3] Cutting tool selection is considered as an developed an expert system Extool which important stage in the process planning and it is a automatically selects the turning tool/insert or milling critical activity that has a great influence on insert, the material and geometry. machining productivity and efficiency. Edalew, Abdalla and Nash [4] developed a To keep up with fast paced technology, system for the selection of cutting tools. It’s a modern factories tend to use new solutions to reduce dynamic programming based system that utilizes cost and time labor and to achieve their performance mathematical modules and heuristic data to objectives. Yet, CAPP system were increasingly used determine and calculate cutting parameters and total to automate process planning activities. component cost. The system contains the following In the early 1980s, research work was modules: the knowledge acquisition module, the undertaken in the area of computer-aided knowledge base module, the inference engine, the manufacturing and process planning systems have user interface and the database. been developed to select a tool or a set of tools for a Arezoo, Ridgway and Al-Ahmari [5] specific operation or a set of operations. developed a knowledge based system for selection of Xiaoping Ren, Zhanqiang Liu and Yi Wan cutting tools and conditions of turning operations. It [1] developed a computer-based intelligent system contains an inference engine, a user interface and for Automatic tool selection for different tool explanation facility, a knowledge base and an materials. The procedure of selection goes through optimization module for machining conditions. several main steps: feature specification, machining The literature review shows that there have type selection, cutting tool selection and optimum been considerable efforts in developing cutting tool cutting conditions. selection systems, nevertheless, there still a lack of Carpenter and Maropoulos [2] developed a manufacturing interoperability between flexible tool selection decision support system for CAD/CAPP/CAM/CNC chains. In fact, design and milling operations, the system is called OPTIMUM cutting tool information are lost when exchanging (Optimized Planning of Tooling and Intelligent information between dissimilar systems. For Machinability evaluation for Milling).It combines a example, at the process planning stage, cutting tools knowledge based logic and statistical methods. are defined with their associated parameters (diameter, length, grades etc…), however, when

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Hanae ZARKTIet.al. Int. Journal of Engineering Research and Application www.ijera.com ISSN: 2248-9622, Vol. 7, Issue 9, (Part -7) September 2017, pp.46-52 moving to machining stage, the CNC program define machining features. The machining feature the tool with only its position, (e.g. T0100), and no definitions are used as inputs to process planning further information is given about it. stage. Micro process planning for machining is then Unlike the traditional standard ISO 6983 (G- carried out using AP 238. STEP-NC is the code), STEP-NC has the ability to link the machining application of STEP methods to NC machines. Its chain components providing a bi-directional flow of title is “STEP Data Model for Computerized data between them. Considering the power of Numerical Controllers”, representing a common data STEP_NC standard and the importance of cutting specifically aimed at NC programming. STEP-NC tool management in enhancing machining has been and continues to be a global effort with the productivity, this project aims the development of an goal of providing a data model for a new breed of automatic optimized cutting tool selection system intelligent CNC controllers. based on the STEP_NC standard. This project is the perspective of previous works launched recently by Research team in Engineering, Innovation and Management of Industrial Systems, FST of Tangier, which deals with CAD/CAPP/CAM integration using STEP_NC standard. El mesbahi et al presented an automated and optimized cutting tools selection system for milling process[6]. In [7], Jaider proposed a CAPP system “CAPP TURN” based on STEP and STEP_NC standards for turning process. In this paper a cutting tool selection methodology is presented. First, the paper outlines the utility of proposed standards, shows the results of cutting tool parameters study, then gives the architecture of cutting tool selection system with Figure 1. Design and process DATA flow with description of its principal modules. Finally, database associated standards implementation and data tool extraction module are described with a case study. III. CUTTING TOOL DATA EXCHANGE Regarding the poor representation of tool in II. STEP_NC STANDARD the older ISO 6983 G and M code language, there is The STEP_NC_AP238 and ISO 14649 an increasing need for manufacturers to adapt a standard is the result of a 10 year international effort standard for cutting tool data representation. This to replace the ISO 6983 G and M code standard with urgent need emanates from the fact that the G& M a modern language connecting CAD data with CAM code describes only the path of the tool center point process data [8]. with respect to machine axes. Consequently, even if STEP /ISO 10303, the standard for the the tool selection is done automatically with CAM exchange of product model describes a complete and systems, information about tool (geometry, unambiguous product definition throughout the life properties…) will be lost when moving to the cycle of a product. STEP standards consist of machining stage. numerous Application Protocols (APs). Each AP is Responding to this problematic, the focused on defining information for a particular proposed tool selection methodology is based on both application domain. An AP had three parts: STEP_NC and ISO13399 emerging standards. • Application activity model (AAM)—a model of the activities and data flows of the application. • Application reference model (ARM)—a model of the data needed for a particular application. •Application interpreted model (AIM)—an encoding of the ARM in terms of the STEP integrated resources. This is the model that is intended for implementation in systems that use STEP. Figure 1 describes design and process data flow with main associated STEP application protocols. The STEP AP 203 describes geometric representation data while AP 224 is used to describe

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Hanae ZARKTIet.al. Int. Journal of Engineering Research and Application www.ijera.com ISSN: 2248-9622, Vol. 7, Issue 9, (Part -7) September 2017, pp.46-52

II.1. CUTTING TOOL REPRESENTATION IN 13399 is a standard for the description of cutting tool STEP_NC/ ISO14649 as products, while ISO 14649 only describes some simple tool requirements to be used by the CNC when deciding what cutting tool to use [11]. An ISO 13399 exchange file contains an electronic representation of cutting tool data as defined by the information structure that can be exchanged by tooling applications. ISO 13399 is defined as a Schema in the ISO 10303 Express language. The ISO 13399 schema develops a framework in which to define tooling properties, tooling assemblies, and relationship between tooling elements. There are no actual tooling properties in the ISO 13399 schema. Instead ISO 13399 develops a programming structure in which to embed ISO 13584, which is the Industrial automation systems and integration – Parts library (PLIB) [12]. As depicted in Figure 3, the P21 file contains links to other files that is needed.

Figure 2. Express G diagram for milling machine cutting tool

Description of cutting tool data for turning and milling are specified in ISO 14649 part 111[9] and ISO14649 part 121[10] respectively. ISO 14649 defines a richer model for information transfer between CAD/CAM systems and computerized numerical control (CNC) machines than that of the older ISO 6983 “G and M code” language. As we had already mentioned, in ISO 6983, tools are defined with only their identifiers without any further information, while in a STEP_NC file, tools are defined in express language with values of properties required in machining (e.g. Figure 3. Product data representation in ISO 13399 cutting length, hand of tool, depth of cut …) figure 2 describes milling tool representation in STEP_NC. IV. STUDY OF INFLUENCING II.2. Data tool representation in ISO13399 Standard PARAMETERS ISO13399 includes the data representation of One important step in designing Tool everything between the workpiece and the machine database is to study cutting parameters which are of tool: Information about inserts (e.g. regular and great importance in selecting cutting tools. Our main irregular shaped replaceable cutting items), solid focus was on milling process. The result of study tools (e.g. solid drill and solid end mill), assembled shows three types of factors that influence tool tools (e.g. boring bars, indexable drills and indexable selection. milling cutters), adaptors (e.g. milling arbor and chucks), components (e.g. shims, screws and clamps) III. 1. Parameters related to workpiece or any combination of the above can be exchanged. Feature type: The type of feature is The cutting tool data described include, but are not considered as a decisive parameter when selecting limited to: cutters. Suitable tools are selected by feature  geometrical and dimensional data, category. Indeed, machining features can be divided  identification and designation data, into two categories, simple features and complex  cutting material data, and component features. Simple features are realized by using one connectivity. machining operation, for example, a face and a The purposes of ISO 13399 and ISO 14649, shoulder can be performed by face milling and in regards to tool information, are different. ISO shoulder milling respectively. Complex features

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Hanae ZARKTIet.al. Int. Journal of Engineering Research and Application www.ijera.com ISSN: 2248-9622, Vol. 7, Issue 9, (Part -7) September 2017, pp.46-52 require at least two machining operations such as the cutting data which ensures that the operation is curved surfaces and freeform surfaces (features), carried out efficiently and within the recommended which require roughing and profiling operations. scope of the tool material. Surface roughness: Surface roughness is Spindle speed (n): in rpm is the number of considered as a critical parameter to select tools and revolutions the milling tool on the spindle makes per number of applications. For example, a feature minute. This is a machine oriented value which is having surface roughness of 0.8 (Ra =0.8) have to be calculated from the recommended cutting speed machined in three applications, roughing, semi- value for an operation. finishing, and finishing application. Feed per minute (f): also known as the table Material of the workpiece: Material of feed, machine feed or feed speed, in mm/min is the workpiece is a determinant factor for selecting the feed of the tool in relation to the workpiece in type of the cutter, the insert grade and the machining distance per time-unit related to feed per tooth and parameters. The manufacturer gives the designations number of teeth in the cutter. of materials and their characteristics such as Specific Maximum chip thickness (hex): in mm is the cutting force and Brinell hardness. Depending on the most important limitation indicator for a tool, for an insert grade and the type of material, the actual operation. A cutting edge on a milling cutter manufacturer gives the maximum chip thickness and has been designed and tested to have a recommended the recommended cutting speed. starting value and a minimum and maximum value. Dimensions of the feature: Dimensions of the feature represent an important parameter that lead V. GLOBAL SYSTEM ARCHITECTURE the choice of milling tool. In fact, the depth of the Based on the results of Functional analysis feature is critical to determine the type of the cutter stage, we defined the global architecture of the and the insert size, on the other hand the length of the automatic tool selection system. feature represents an indicator of which diameter to Figure.4 shows flow chart of tool selection choose. systems with inputs, outputs and relations between its modules: Tool management module, recognition III.2. Parameters related to Cutting tool: module, Selection module and optimization module. Depth of cut (ap): in mm (axial) is what the The data tool management module consists of a solid tool removes in metal on the face from the tool database linked to a data tool extraction workpiece. This is the distance the tool is set below software. Extraction procedure starts by uploading the un-machined surface. the ISO13399 file which contains information about Tool material: Different machining tool, then these information are extracted and stored applications require different cutting tool materials. in the database. The cutting tool material affect directly the cutting Considering that the system is based on hardness, temperature stability and tool life. STEP_NC standard, the process of tool selection Cutting width (ae): in mm (radial) is the starts by uploading the AP238 file of the Part. This width of the component engaged in cut by the numerical file contains necessary information to diameter of the cutter. It is distance across the surface manufacture the part. It also comprises geometrical, being machined or, if the tool diameter is smaller, topological and technical (material, tolerances...) that covered by the tool. definitions of the part to manufacture. Entering angle: As regards cutting geometry All of these technical definitions will be in milling, the entering angle (κr), or the major extracted using an object oriented program that allow cutting edge angle, of the cutter is the dominant also recognition of manufacturing features. Then, factor affecting the cutting force direction and chip based on information stored in Tool database, and thickness. The choice of insert geometry has been using an appropriate tool selection algorithm, Milling simplified into three practical areas of varying cutting cutters are sorted and affected to Manufacturing action effects: Light (L), general purpose (M) and features of the part. tough (H) geometries. A user interface allows planners to Zc: The number of effective cutter teeth (Zc) determine either to stop selection process and in the tool varies considerably and has a direct effect generate STEP_NC AP238 file for machining or to on table feedrate and productivity. The material, activate optimization module before generation. width of component, stability, power, surface finish In the second case, the user is invited to influence how many teeth are suitable. select optimization criteria and determine its preferences before starting optimization algorithm. III.3. Parameters related to machining process Finally, optimal tools will be assigned to Cutting speed (vc): in m/min indicates the manufacturing features and the result is the numerical surface speed at which the cutting edge machines the file STEP_NC AP238 which contains machining workpiece. This is a tool oriented value and part of process information.

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Hanae ZARKTIet.al. Int. Journal of Engineering Research and Application www.ijera.com ISSN: 2248-9622, Vol. 7, Issue 9, (Part -7) September 2017, pp.46-52

VI. DEVELOPMENT OF DATA TOOL MANAGEMENT MODULE VI.2. Development of data tool extraction software VI.1. Development of tool database In this section, we present the data tool management module and its principal functionalities. Figure 6 is a use case diagram which illustrates interactions between actors and tool management system. There are two principal actors:The tool administrator: its principal role consist on feeding database with updated information tools by uploading the P21 file of products(tools, inserts, holders..) according to ISO 13399 standard. The tool administrator could also modify an existing tool in the database.

A tool database was created to provide better management of tools. The first step was the Figure. 5. Data tool relational diagram elaboration of data dictionary. The next step was data tools classification into entities and attributes. Then, identification of relationships between tables was undertaken before database implementation. The relational diagram depicted in figure 5 was developed under MySQL workbench software. It consist of 21 tables. The tool table is the principal entity, tool can be either a milling tool represented by mill table or a turning tool represented by turn table. Each tool can be linked in machine direction to a holder or an adaptive item. In the workpiece direction, the tool is linked to the insert. There are different child insert tables (round insert, equilateral equiangular insert, etc) that derive from principal insert table due to different existing insert categories. Inheritance relationships between classes were conceived based on tool and cutting item classification in ISO13399 part 2 [14] and ISO 13399 part 3[15] respectively. For example, a face mill derived from Mill class which derived from tool item class. Figure 6.Tool management module: Use case We choose to feed database automatically diagram with data from The Sandvik Coromant [16] ISO 13399 catalogue for milling and turning tools. For this purpose an object oriented program was created using c# programming to extract technical data from ISO file and ensure data feed and update of database. More details on software functionalities are given in the following section.

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selection. Development of feature recognition, tool selection, and optimization modules will be the object of future works.

REFERENCES [1] X. P. Ren, Z. Q. Liu, Y. Wan, "A Computer- Based Intelligent System for Automatic Tool Selection", Materials Science Forum, Vol. 723, pp. 238-242, 2012. [2] I.D.Carpenter,P.G.Maropoulos, A flexible tool selection decision support system for milling operations, Journal of Materials Processing technology 107 (2000) 143-152. [3] R.Mookherejee, B.Bhattacharyya, Development of an expert system for turning and rotating tool selection in a dynamic environment, Journal of Materials Processing Technology 113 (2001) 306- 311. [4] K.O. Edalew, H.S. Abdalla, R.J.Nash, A computer- based intelligent Figure 7. Data tool extraction software. system form automatic tool selection, Materials and design 22 (2001) The ordinary user: The user has the 337-351. possibility to search for available tools in the [5] B. Arezoo, K.Ridgway, A.M.A. Al-Ahmari, database. The research could be for a unique tool or Selection of cutting tools by tools categories/classes (e.g. tools for turning and conditions of machining operations tools for face milling, etc.). Figure.7 is an example of using an expert system, adding a new milling tool “CoroMill 357” and its Computers in industry 42 (2000) 43-58.G. corresponding insert to database. In widget 1, the tool Eason, B. Noble, and I. N. Sneddon, “On administrator upload the corresponding ISO13399 certain integrals of Lipschitz-Hankel type file of the tool. He activates tool extraction procedure involving products of Bessel functions,” by click on extraction button, then tool parameters Phil. Trans. Roy. Soc. London, vol. A247, are shown in widget 2 with corresponding 2D and 3D pp. 529–551, April 1955. (references) views. Search for related inserts is done and results [6] Abdelilah Elmesbahi, Ahmed Rechia, and are displayed in a list (3). By clicking on the extract Oussama Jaider, “optimized automated button, search for the Iso 13399 file of the insert is choice of cutting tool machining done automatically and the same extraction manufacturing features in milling process”, procedure is run. Insert parameters are shown in proceeding of the 11th World Congress on details in widget 4. By clicking on “add to database Computational Mechanics (WCCM XI), button”, the tool administrator could add the tool and Barcelone, 2014. the insert to database (widget 5). [7] Oussama JAIDER, “Planification automatique des processus d’usinage des VII. CONCLUSION pièces de révolution, basée sur les normes The aim of this paper was to dress the STEP et STEP-NC”, Thèse de doctorat, architecture of our automatic optimized cutting tool Faculté des Sciences et Techniques, Tanger, selection system which is currently under Maroc, 2017. development, based on STEP_NC standard. The [8] ISO 10303-238: Industrial automation paper dealt also with the development of the data tool systems and integration — Product data extraction module and database that will be of great representation and exchange — Part 238: importance to the automation of cutting tool Application protocol: Application selection. interpreted model for computerized The data tool extraction module was the numerical controllers. automatic solution to feed and update database. Since [9] ISO 14649-111: Industrial automation tools manufacturers tends to adopt ISO13399 systems and integration — Physical device standard, we consider to update database with recent control — Data model for computerized tool data to provide an effective way of tool

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numerical controllers — Part 111: Tools for milling machines. [10] [10]. ISO 14649-121: Industrial automation systems and integration — Physical device control —Data model for computerized numerical controllers — Part 121: Tools for turning machines. [11] OLOF NYQVIST, Information Management for CuttingTools. Information Models and Ontologies, Doctoral thesis, Stockholm, Sweden 2008. [12] Graham T. Smith, cutting tool technology: industrial handbook, Springer, 2008. [13] ISO/TC184/SC4 (2001a). Industrial Automation Systems and Integration – Parts Library – Part 1: Overview and fundamental principles. International Organization for Standardization. ISO 13584-1. [14] ISO/TS 13399-2: Cutting tool data representation and exchange — Part 2: Reference dictionary for the cutting items. [15] ISO/TS 13399-3: Cutting tool data representation and exchange — Part 3: Reference dictionary for the tool items. [16] www.sandvik.coromant.com/

Hanae ZARKTI. “Methodology for Cutting tool selection system based on STEP_NC. Part 1: Development of tool Management system according to ISO13399 standard.” International Journal of Engineering Research and Applications (IJERA) , vol. 7, no. 9, 2017, pp. 46–52.